Devices, systems, and computer-implemented methods for dental attachment templates

ABSTRACT

The present disclosure provides methods, devices, systems, and computer-implemented methods for forming and placing attachments for use with dental appliances, and more particularly to the design, manufacture, and use of three-dimensionally printed attachment templates for use with orthodontic devices. Dental attachment templates include a cavity with one or more openings for injecting and bonding attachment material directly on a patient&#39;s tooth, which allow accurate placement of the attachments while providing the dental practitioner flexibility during the attachment forming process. Digital dental attachment template model techniques can be used to accurately place the cavity and opening.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.16/409,724, filed May 10, 2019, now U.S. Pat. No. 11,504,214, whichclaims priority to U.S. Provisional Patent Application No. 62/670,520,filed on May 11, 2018, each of which is incorporated herein by referencein its entirety.

INCORPORATION BY REFERENCE

All publications and patent applications mentioned in this specificationare herein incorporated by reference in their entirety to the sameextent as if each individual publication or patent application wasspecifically and individually indicated to be incorporated by reference.

FIELD

The technical field relates to devices, systems, andcomputer-implemented methods for forming and placing attachments for usewith dental appliances, and more particularly to the design,manufacture, and use of dental attachment templates for use withorthodontic devices.

BACKGROUND

Dental treatments involve restorative and/or orthodontic procedures toimprove the quality of life of a patient. For example, restorativeprocedures may be designed to implant a dental prosthesis (e.g., acrown, bridge, inlay, onlay, veneer, etc.) intraorally in a patient.Orthodontic procedures may include repositioning misaligned teeth andchanging bite configurations for improved cosmetic appearance and/ordental function. Orthodontic repositioning can be accomplished usingpositioning appliances. Such appliances may utilize a shell of materialhaving resilient properties, referred to as an “aligner,” that generallyconforms to a patient's teeth but is slightly out of alignment with acurrent tooth configuration. Placement of such an appliance over theteeth may provide controlled forces in specific locations to graduallymove the teeth into a new configuration. Repetition of this process withsuccessive appliances in progressive configurations can move the teeththrough a series of intermediate arrangements to a final desiredarrangement. Such systems typically utilize a set of appliances that canbe used serially such that, as the teeth move, a new appliance from theset can be implemented to further move the teeth.

Such appliances may work in conjunction with attachments placed onteeth. Attachments can be fastened to one or more teeth, for example,via adhesive, direct or indirect bonding, and/or or other techniques,and can be used in conjunction with the shape of an appliance to impartrepositioning and/or anchor forces to a patient's teeth. The sameattachments may be utilized with multiple appliances. Or, attachmentsmay be added, removed, or replaced with other attachment shapes that mayimpart different force characteristics than a previous appliance andattachment combination (e.g., appliance and one or more attachments).

Sometimes, an orthodontic treatment plan may use attachments that havecomplex shapes to rotate, translate, intrude, and/or extrude teeth. Anorthodontic treatment plan may also call for attachments to be placed atlocations on a patient's teeth that are difficult to access by patientsand/or dental practitioners. Many existing techniques make it hard toform attachments with complex shapes and/or place attachments atdifficult-to-access locations. Additionally, current techniques make ithard to facilitate formation and/or placement of attachments bypractitioners with less training and/or expertise than orthodontists ordentists.

SUMMARY

Described herein are dental attachment placement apparatuses and methodsof their use. The apparatuses, referred to herein as dental attachmentplacement templates (or “templates”), can be used to position one ormore attachments to the tooth surfaces. The attachment(s) can beconfigured to cooperate with an aligner to apply an alignment force to apatient's dental arch according to an orthodontic treatment plan. Aninner surface of the template can be designed to complement a portion ofthe patient's dental arch to place the attachments at predeterminedlocations on the patient's teeth. The template can include one or morecavities for molding the shape of the attachments. Once placed on apatient's dental arch, an attachment material in a fluid state may beintroduced to the cavity(ies) of the template via one or more holes inthe template, followed by curing of the attachment material. After theattachment(s) is/are bonded to the tooth/teeth, the template can beremoved from the patient's mouth.

The apparatuses described herein may provide more flexibility for adental professional compared to other dental placement apparatuses. Forexample, since the attachment material may be applied after the templateis positioned on the patent's teeth, the dental professional may choosethe type of the attachment material at the dental office. In some cases,the dental professional may choose one or more attachment materialsbased on specific needs according to the orthodontic treatment plan.Further, the dental professional can adjust the amount of attachmentmaterial by controlling the flow of the attachment material into thecavity(ies). The dental professional may also be able to adjust thelocation of the attachment(s) on the tooth/teeth, for example, bypressing on and/or slightly shifting the template while on the patient'steeth before or during the injection and/or curing processes. In thisway, the professional may be able compensate for dimensionalinconsistencies in the template, resulting in a more precise attachmentlocation and/or a better bond between the attachment and the toothsurface. The template may also allow the professional to formattachments having shapes that are difficult to form using other dentalplacement templates. The templates described herein can include a numberof features that may provide these and other advantages.

According to some embodiments, the template includes a first (e.g.,outer) surface configured to interface with an interior portion of apatient's mouth, and a second (e.g., inner) surface opposite the firstsurface configured to register with the patient's dental arch.Registering can include placing the template on the dental arch suchthat a shape of the inner surface matches with a corresponding shape ofone or more tooth surfaces. Thus, in some cases, the second surface hasa shape corresponding to a shape of at least a portion of the patient'sdentition. The second surface can include a cavity configured to hold anuncured attachment material to a tooth surface, such as a facial surfaceof the tooth. The cavity can define a molding surface that is configuredto shape the uncured attachment material. The template can also includeone or more holes that provides access to the cavity from the firstsurface of the template. The hole(s) may include an injection holeconfigured for injecting the uncured attachment material in a flow ablestate into the cavity. The injection hole(s) can be sized and shaped toallow an attachment material in a flowable state to flow into thecavity. In some cases, the hole(s) include a window configured to allowlight to shine though for curing the attachment material in the cavity.In some embodiments, the hole(s) has a predetermined size. In aparticular embodiment, the hole(s) has a cross section diameter at thesecond surface of template of at least about 1 mm².

Described herein are methods of forming and attaching the dentalattachment(s) to a patient's tooth/teeth using the template. Accordingto some embodiments, methods of forming an attachment include placingthe template on the dental arch of a patient such that an inner surfaceof the template registers with one or more tooth surfaces of the dentalarch. The inner surface has a cavity adjacent a crown surface of a toothand a hole that provides access to the cavity from an outer surface ofthe template. Methods can also include injecting an attachment materialin a flowable state into the cavity via the hole within the templatesuch that the attachment material contacts the crown surface of thetooth. The cavity may be within an attachment region of the templatehaving a prescribed wall thickness to resist deformation during theinjection process. In some cases, the wall thickness of the attachmentregion may be at least about 0.5 mm (e.g., from about 0.5 mm to about2.0 mm). In some instances, the wall thickness of the attachment regionis thicker than surrounding walls. Since the attachment material may beinjected into the cavity mold after the template is placed on the dentalarch, the dental professional can control different aspects of theattachment forming process. For example, the professional may choose thetype of attachment material, sometimes choosing multiple attachmentmaterials. The dental professional may also control the amount ofmaterial injected into the cavity by, for example, adjusting aninjection pressure. This flexibility may also allow the attachment to beformed on tooth surface locations that are difficult to access usingtraditional attachment placement techniques. In some cases, the templateincludes a vent hole that allows air and/or excess uncured attachmentmaterial to flow out of the cavity during the injecting. Methods canfurther include bonding the attachment on the crown surface of the toothby curing the attachment material on the tooth by shining light on theattachment material in the cavity. The light may be shone through thehole and/or through a transparent portion of the template.

Methods can also include removing the template from the dental archafter the attachment is sufficiently cured and bonded to the tooth. Theresultant attachment on the tooth can have shape corresponding to theshape of the cavity mold of the template. Some orthodontic treatmentplans require the use of attachments with shapes that may make itdifficult to remove the template. Such attachments may include brackets,braces, hooks or other features that may have non-symmetric shapes,overhangs, undercuts and/or sharply angled edges, which may be difficultto maneuver the template during removal. To address these issues, insome embodiments, the methods include bending the template along one ormore compliant regions of the template, such as slits in the template.In some embodiments, removing the template includes breaking thetemplate using a tool or breaking the template at one or more scores inthe template. Methods may additionally include placing an aligner on thedental arch of the patient such that the aligner interacts with theattachment to apply one or more forces in a predetermined direction onthe dental arch.

Described herein are methods of forming the dental attachment templatesusing computer modeling techniques. According to some embodiments,methods of forming the attachment template include placing an attachmenton a surface (e.g., crown surface) of a tooth of a digital dental model.The digital dental model may correspond to, or be based on, a scan of apatient's dentition. Methods can also include creating a digitalattachment template from the digital dental model including theattachment on the surface of the tooth of the digital dental model,where the attachment forms a cavity on an inner side of the digitalattachment template. Methods can further include creating one or moreholes in the digital attachment template that provides access for aflowable attachment material into the cavity. Creating the one or moreholes may involve contacting or overlapping various digital shapes onthe digital attachment template, which can be used to cut the one ormore holes. For example, a cut shape may be place on the digitalattachment template and subtracted from the digital attachment template.In some cases, the one or more holes may be configured to act as windowsthat allow light to shine through to the cavity. For example, formingthe hole(s) can include forming a window that defines an area of thelight cast onto the flowable attachment material. The one or more holesmay have a predetermined size; for example, have a cross-sectional areafrom about 1 square millimeters (mm²) to about 4 mm². Creating the oneor more holes may involve forming an injection hole for the flowableattachment material to be injected into the cavity. Creating the hole(s)may further include forming a vent hole that allows excess uncuredattachment material or air to flow out of the cavity during theinjecting of attachment material.

Methods of forming the dental attachment templates may also includethree-dimensional printing the attachment template based on the digitalattachment template. Three-dimensional printing can provide someadvantages over other manufacturing techniques. For example, someattachments may have non-symmetric shapes, overhang or undercut regions,sharply angled features and/or enclosed areas, which may be difficult toform using other manufacturing techniques. Features such as slits andscore marks may also be formed more easily using three-dimensionalprinting.

These and other features and advantages of the dental attachmentplacement templates are described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Novel features of embodiments described herein are set forth withparticularity in the appended claims. A better understanding of thefeatures and advantages of the embodiments may be obtained by referenceto the following detailed description that sets forth illustrativeembodiments and the accompanying drawings.

FIG. 1 illustrates a three-dimensional printed attachment template, anattachment material delivery device, and a light source according to anumber of embodiments of the present disclosure.

FIG. 2 illustrates a three-dimensional printed attachment template, anattachment material delivery device, and a light source according to anumber of embodiments of the present disclosure.

FIG. 3 illustrates a rectangular attachment according to a number ofembodiments of the present disclosure.

FIG. 4 illustrates an ellipsoid attachment according to a number ofembodiments of the present disclosure.

FIG. 5 illustrates a morphed attachment according to a number ofembodiments of the present disclosure.

FIG. 6 illustrates hook and button attachments according to a number ofembodiments of the present disclosure.

FIG. 7 illustrates a donut attachment according to a number ofembodiments of the present disclosure.

FIG. 8 illustrates a bracket attachment according to a number ofembodiments of the present disclosure.

FIG. 9 illustrates an attachment template body for the placement of oneor more attachments on one or more of a patient's teeth including slitsaccording to a number of embodiments of the present disclosure.

FIG. 10A illustrates a computing system for use in a number ofembodiments of the present disclosure.

FIG. 10B illustrates an example of an attachment modeling system,according to some embodiments.

FIG. 11 illustrates screen captures of an implementation of an exampleprocess of creating a digital attachment template attachment accordingto a number of embodiments of the present disclosure.

FIG. 12 illustrates screen captures of an implementation of an exampleprocess of creating an opening in a digital attachment templateattachment according to a number of embodiments of the presentdisclosure.

FIG. 13 illustrates screen captures of an implementation of an exampleprocess of creating an opening in a digital attachment templateattachment according to a number of embodiments of the presentdisclosure.

FIG. 14 illustrates an example flowchart of a process for providinginstructions to create an attachment template using a virtual 3D surfacemodel of the attachment template.

FIG. 15 illustrates an example flowchart of a process for 3D printing anattachment template.

FIG. 16 illustrates an example flowchart of a process for creatingattachments on a patient's teeth using an attachment template.

DETAILED DESCRIPTION

The implementations herein are highly advantageous over thermoformedattachment templates that may limit the complexity of the shape(s)and/or position(s) of attachments. The implementations herein may alsoallow for the design and/or use of attachment templates that are morerigid and/or thicker than thermoformed attachment templates. Theimplementations of attachment templates have less manufacturing stepsthan thermoformed attachment templates.

3D Printed Attachment Templates and Systems/Methods for Making and Usingthe Same

The present disclosure describes examples of methods, devices, andsystems for placing and forming attachments for use with dentalappliances using three-dimensionally printed attachment templates. Thetechniques described herein allow skilled and/or unskilled dentalprofessionals, as well as lay people to place dental attachments onteeth. Dental attachments formed and/or placed according to thetechniques herein may have complex shapes not otherwise possible and maybe placed at locations that were difficult to reach with conventionaltechniques. In some implementations, an attachment template isdisclosed. An “attachment template,” (also referred to as a “template”)as used herein, may include a device configured to facilitate formationand/placement of attachments on a patient's teeth. An “attachment,” or“dental attachment,” as used herein, may refer to a structure attached(e.g., through adhesion, bonding, etc.) to a patient's teeth that, inconjunction with a device (e.g., an aligner) cooperates to facilitatetransfer of positioning forces to the patient's teeth.

In some implementations, an attachment template may include a body witha first surface that is configured (e.g., shaped) to interface withcheeks, gums, or other interior portions of a patient's mouth. The bodymay be formed of a plastic material such as a flowable and/or packablecomposite material. In some implementations, the body may comprise athree-dimensionally (3D) printed body that is formed by 3D printingtechniques. The body may but need not allow light to pass through. Asexamples, the body may be translucent or opaque; in someimplementations, the body may be transparent to visible light as well. Asecond surface of the body may be configured (e.g., shaped) to receive apatient's teeth through one or more cavities that have attachment molds,which as used herein, may refer to specific portions of a cavity shapedto form dental attachments when attachment material is placed and curedtherein.

In some implementations, the cavities may receive one or more of thepatient's teeth. As noted herein, attachment molds may include one ormore openings (e.g., windows, slits, etc.) that allow a dentaltechnician to place attachment material inside. The openings may allowattachment material in an attachment mold to be exposed to curingradiation (e.g., light) so that the attachment material can be curedinto an attachment(s). As noted herein, the attachment molds may form avariety of shapes, including complex shapes, such as rectangles,ellipsoids, morphed shapes, hooks, buttons, and/or donut shapes. Theattachments formed by the attachment molds may allow for the applicationof a variety of orthodontic repositioning forces to be applied to thepatient's teeth, particularly when such attachments are used inconjunction with aligners. For example, a first aligner may beconfigured to interact with one or more attachments to apply at least afirst force in a first direction. A subsequent second aligner may beconfigured to interact with one or more attachments to apply at least asecond force in a second direction. A third, fourth, fifth or morealigners may be configured to interact with the one or more attachmentsin accordance with the treatment plan.

Embodiments of the present disclosure provide methods, devices, andsystems that can aid in the forming and placement of attachments. Forexample, in one embodiment, an attachment template for forming andplacing attachments used in moving teeth of a patient can include athree-dimensional printed attachment template body having a firstsurface shaped to conform to contours of exterior surfaces of one ormore teeth of a patient. The body can include a portion of the firstsurface that provides a cavity to form the exterior surfaces of anattachment. The attachment can be attached to and protruding from theexterior surfaces of the one or more teeth. The cavity can include anopening for insertion of uncured attachment material into the cavity.

The attachment template body can be formed using a variety ofthree-dimensional printing technologies. For example, the attachmenttemplate body can be three-dimensionally printed via fused depositionmodeling (FDM), stereolithography (SLA), or selective laser sintering(SLS). The contours of the exterior surfaces of the one or more teeth ofthe patient can be scanned and used to create the three-dimensionallyprinted attachment template body. In some embodiments, the first surfaceof the body can be shaped to conform to the facial (e.g., buccal) and/orocclusal surfaces of the teeth of the patient.

The attachment can be one or more shapes. For example, the attachmentcan be, but is not limited to, a rectangle, ellipsoid, morphed, hook,button, or donut shape. The attachment can be used in a variety oftreatments, including AP correction and extrusion treatment, forexample. The attachment can be formed by injecting the uncuredattachment material into the cavity of the attachment template body viathe opening. The cavity can include a vent to allow air to flow from thecavity. The vent can prevent air bubbles from forming in the attachment.

In some embodiments, the attachment template body can include a secondcavity. The second cavity can be used at a different treatment stagethan the first cavity. The attachment template body can also includeslits. The slits can be between each crown of the one or more teeth. Theslits can be used for flexibility of the attachment template body whenworn by the patient. The slits can also be used for allowing the body tobe split into a number of pieces at each of the slits. Splitting thebody could allow a number of attachments to be printed at once and usedat different times during treatment.

A portion of the body of the attachment template can be made ofnon-light transmissive material, for example, nylon. The opening canpermit light to enter the cavity to cure the attachment material where aportion of the body is made of non-light transmissive material. In someembodiments, a portion of the body can permit light to enter to cure theattachment material by being made of a light transmissive material. Insome examples, a blue light can be used to cure the attachment material.The uncured attachment material can be exposed to a light from 20 to 40seconds, for example. Non-visible light or ultraviolet (UV) light mayalso be used to cure the attachment material. For example, the lightused to cure the attachment material can have a wavelength of 400nanometers to 500 nanometers. The light can come from one or more typesof light sources (e.g., light source 110 in FIG. 1 ), for example,tungsten halogen, light-emitting diode (LED), plasma, arc curing, orlaser.

In the present disclosure, reference is made to the accompanyingdrawings that form a part hereof, and in which is shown by way ofillustration how one or more embodiments of the disclosure may bepracticed. These embodiments are described in sufficient detail toenable those of ordinary skill in the art to practice the embodiments ofthis disclosure, and it is to be understood that other embodiments maybe utilized and that process, electrical, and/or structural changes maybe made without departing from the scope of the present disclosure.

The figures herein follow a numbering convention in which the firstdigit or digits correspond to the drawing figure number and theremaining digits identify an element or component in the drawing.Similar elements or components between different figures may beidentified by the use of similar digits. For example, 102 may referenceelement “02” in FIG. 1 , and a similar element may be referenced as 202in FIG. 2 . Further, as used herein, the designators “M”, “N”, and “P”,with respect to reference numerals in the drawings, indicate that anynumber of the particular feature so designated can be included.

As will be appreciated, elements shown in the various embodiments hereincan be added, exchanged, and/or eliminated so as to provide a number ofadditional embodiments of the present disclosure. In addition, as willbe appreciated, the proportion and the relative scale of the elementsprovided in the figures are intended to illustrate certain embodimentsof the present disclosure and should not be taken in a limiting sense.

One or more systems, methods, and computer-readable media for designingattachment templates are disclosed herein. Implementations may involvecreating a 3D surface model of a virtual attachment formation templatewith attachment molds and 3D printing an attachment template from the 3Dvirtual surface model. In some implementations, one or more teeth of apatient may be identified for treatment. A virtual representation of theone or more teeth may be gathered. A “virtual representation of teeth,”as used herein, may include a data structure that allows teeth to bevisualized or otherwise represented on a computing device.

In some implementations, virtual representation of teeth may include adepiction of teeth at the beginning, end, and/or an intermediate stageof an orthodontic treatment plan, and may involve data relating tosize(s), shape(s), position(s), etc. of those teeth at those stages. Anorthodontic treatment plan may, but need not, be accessed, and one ormore positional force systems may, but again, need not, be gathered fromthe orthodontic treatment plan. An “orthodontic treatment plan,” as usedherein, may include a computer-implemented plan to move a patient'steeth from one position/orientation to another. An “orthodontictreatment plan” may include beginning, end, and/or intermediatestage(s), and may be implemented through a set of incremental alignersthat are affixed to a patient's teeth and/or attachments thereon. A“positional force system,” as used herein, may include a set of force(s)and/or torque(s) that are applied to a patient's teeth as part of anorthodontic treatment plan. A positional force system may be implementedthrough a set of incremental aligners that are affixed to a patient'steeth and/or attachments thereon.

In some implementations, virtual representations of one or moreattachments are gathered. The specific attachments to be modeled may beknown in some implementations or may be inferred from an orthodontictreatment plan in various implementations. The virtual representationsmay include virtual rendering(s) of the attachments and may includevirtual size(s), shapes, contours, etc. that facilitate visualization ofphysical properties of the attachments. The virtual representations mayinclude positional data related to the specific locations and/ororientations the attachments are to reside over the patient's teeth. Oneor more virtual openings on the virtual representations of theattachments may be identified. A “virtual opening,” as used herein, mayinclude a virtual depiction of an opening in an attachment, and maycomprise size(s), shape(s), orientations, contour(s), etc. of an openingto be formed in an attachment template in order to receive attachmentmaterial and/or cure the attachment material using a curing radiationsource. A virtual 3D surface model of an attachment template using thevirtual representation of the one or more teeth, the virtualrepresentations of the one or more attachments, and the one or morevirtual openings may be created. Instructions to 3D print the attachmenttemplate using the 3D surface model of the attachment template may beprovided.

One or more systems and methods for forming attachment templates aredisclosed herein. In some implementations, a virtual 3D surface model ofan attachment template is gathered. The virtual 3D surface model mayinclude first virtual representations of one or more attachments used inconjunction with one or more aligners as part of an orthodontictreatment plan, and the virtual 3D surface model may further include oneor more virtual openings identified on the virtual representations ofthe one or more attachments. The one or more virtual openings maycorrespond to openings for the one or more attachments to receive aninjectable material. Instructions to 3D print an attachment templateusing the virtual 3D surface model of the attachment template may beprovided.

A method of forming attachments using attachment templates are disclosedherein. Methods may involve placing over one or more teeth of a patientan attachment template that comprises: a body; a first surface shaped tointerface with the cheeks of the patient; a second surface shaped tointerface with a facial (e.g., buccal) surface of the one or more teethof the patient, the second surface having one or more cavitiesconfigured to form one or more attachment molds. As noted herein, insome implementations, the cavities may receive one or more of thepatient's teeth as well. Each of the one or more attachment molds may beconfigured to correspond to an attachment shape and an attachmentlocation of one or more attachments used in an orthodontic treatmentplan on the one or more teeth. Each of the one or more attachment moldsmay have an opening configured to expose material within the attachmentmold to a light source. Attachment material may be placed into the oneor more attachment molds. The attachment material may be cured withinthe one or more attachment molds by shining curing radiation (e.g., alight) through the opening for a curing time.

Example Structures

FIG. 1 illustrates a three-dimensional printed attachment template 100,an attachment material delivery device 162, and a light source 110according to a number of embodiments of the present disclosure. In theembodiment shown in FIG. 1 , the attachment template 100 can include abody 104 having a first surface 142 and a second surface 144, and acavity 106 having one or more openings (designated by 107 indicating aperimeter of an opening), which may also be referred to as one or moreholes. The one or more openings 107 can provide access to the cavity106. The second surface 144 may correspond to an inner surface thatcontacts the patent's dental arch (e.g., teeth and/or gums). The firstsurface 142 may correspond to an outer surface of the template that maybe directly accessible by the lips, tongue and/or a dental practitioner.

The body 104 may include a structure formed of a 3D printed material andconfigured to receive a patient's teeth 102. The body 104 may be formedof a packable and/or flowable composite and may comprise material thatis translucent or opaque to light. The first surface 142 of the body maybe shaped to interface and/or be received by a patient's cheeks or otherportion of the patient's mouth. The second surface 144 may be shaped toreceive the patient's teeth 102. In the embodiment of FIG. 1 , the body104 is shaped to receive all of the teeth 102 in the upper jaw of apatient. The body 104 can have portions of different thickness, forexample portion 105 (shown in FIG. 1 as having a thickness greater thanother portions of the body 104).

The cavity 106 may include or be accessible by the one or more openings107. The opening(s) 107 may be configured (e.g. shaped) to form anattachment mold to receive attachment material 108, for example, in aflowable (e.g., uncured) state. In some embodiments, the attachmentmaterial 108 may be injected into the cavity 106 via opening(s) 107while in a flowable state. The attachment mold may include interiorsurfaces 106 that are used to form the exterior surfaces of theattachment as the uncured attachment material 108 is cured by a lightsource 110 (as discussed further herein). In some embodiments, theopening(s) 107 may be configured to expose the contents within thecavity 106 to a source of curing radiation (e.g., light from the lightsource 110). Thus, the opening(s) 107 may be window(s) for shining lightinto the cavity 106 and onto the uncured attachment material. In caseswhere the template 100 is made of a material that opaque to thewavelengths of the light, the size and number of the window(s) maydefine an area of the light cast into the cavity and onto the uncuredattachment material. For instance, the perimeter (e.g., defined by theedges) of the opening(s) can define area of cast light. In someembodiments, a cross-sectional shape of the window(s) is at least aswide as a largest width of the cavity 106. When the uncured attachmentmaterial is exposed to the curing radiation, the attachment materialwithin the cavity 106 can cure (e.g., harden) into an attachment. Insome embodiments, a cross-sectional area of the opening(s) is based atleast in part on a curing property of the attachment material and anenergy property of the light. The curing properties of the attachmentmaterial can include the curing wavelength, light intensity and/orcuring time of the attachment material, as described herein. In someembodiments, the opening(s) have a cross-sectional area ranging fromabout 1 square millimeters (mm²) to about 4 mm².

The cavity 106 can be sized and/or shaped to hold a specific amount ofattachment material 108 to form the desired shaped attachment needed forthe treatment plan to treat the orthodontic conditions of a patient.This not only includes an amount sufficient to form the exteriorattachment surface shapes defined by the interior surfaces of the cavity106, but also sufficient material to form an affixation surface that canbe used to affix the attachment to the surface of a tooth. In someembodiments, the attachment material 150 is bonded to the surface of thesurface of the tooth during the curing process. In some embodiments, theattachment material 150 includes multiple materials. For example, afirst material (e.g., within the cavity 106) may be used to bond theattachment to the tooth surface and a second material (e.g., differentthan the first material) may be used to form an outer surface shape ofthe attachment. The first and second materials may have differentproperties, such as different bonding properties, flexibility orrigidity (e.g., elastic modulus) and/or surface texture when in curedform. Once the attachment material 150 is cured and bonded to the one ormore teeth, the template 100 can be removed from the patient's dentalarch. The cured (e.g., hardened) attachment material can retain theshape of the cavity 106 on the tooth.

The affixation surface can be a flat surface or can have a shape thatmatches that of the surface of the tooth to which the affixation surfaceis to be affixed. A matching surface to that of the tooth can bebeneficial as it may allow for a stronger affixation of the attachmentand thereby the attachment can be used with higher forces when used incombination with a dental appliance. By injecting the attachmentmaterial while in fluid form onto the tooth, the attachment material maybe allowed to better conform to the tooth surface, and thereby provide amore conforming affixation surface, compared to techniques where theattachment material contacts the tooth in non-fluid form.

Additionally, as discussed herein, some embodiments may use a bondingmaterial to affix the attachment to the surface of a tooth. When sizingthe cavity 106, the size can be calculated to include space for thisbonding material, as noted further herein.

Further, in some embodiments, the cavity 106 may have a release material(e.g., lubricant, thin film, coating, etc.) provided between thesurfaces of the cavity 106 and the uncured attachment material 108. Suchrelease material may be beneficial in separating the attachment from thecavity 106. Any suitable release material may be used to accomplish suchfunctionality. In such embodiments, the size of the cavity 106 may becalculated to accommodate the release material based on an estimate ofthe amount of space needed to accommodate the release material.

In various embodiments, the cavity 106 may be provided to the user withno attachment, release, or bonding material therein (e.g., may be addedby the treatment professional, patient, or other user), may be providedwith the uncured attachment material 108 therein, or may be providedwith release and/or the bonding material provided in the cavity 106 withthe uncured attachment material 108.

The sizing of the cavity 106 can be determined based on whether arelease material is to be used and/or whether a bonding material isgoing to be used to affix the attachment to the tooth rather than theattachment being affixed directly to the tooth surface. As discussedabove, the size of the cavity 106 attributable to the release materialcan be calculated, for example, based on amount of release material tobe used and the volume of the type of release material to be used, amongother variables.

One or more of the attachment surfaces will be used to interact with oneor more surfaces of the dental appliance and, therefore, the shape,position, and orientation of the one or more surfaces that interact withthe dental appliance is important. Accordingly, the attachment template100 is used to more accurately shape, position, and orient theattachment with respect to the tooth surface to which it is to beattached.

In some implementations, a first surface of an attachment may beutilized through interaction with one or more surfaces of a dentalappliance while a second surface of the attachment is not utilized.Then, later in treatment, the second surface of the attachment is eitheradditionally or alternatively used to interact with one or more surfacesof a dental appliance. In this manner, an attachment can be designed toprovide more than one function during the treatment of the patient basedon use of different surfaces provided on the attachment.

As shown in FIG. 1 , the shape of any of the attachment templatesdiscussed herein can be designed to approximate the shape of one or moreteeth of the patient. The more accurately the shape of the attachmenttemplate 100 approximates the shape of one or more of the surfaces of atooth 102 of a patient, the more accurate the placement of theattachment can be. This is because each tooth surface has uniquecharacteristics (e.g., contours, edges, peaks, valleys, etc.) and if asurface of the attachment template 100 closely approximates thesecharacteristics, then the surface of the tooth and the surface of theattachment template 100 can be closely mated to each other (i.e.,characteristics are aligned when the attachment template is placed overthe tooth) and this results in more accurate placement of the attachmenton the surface of the tooth.

The more characteristics on a tooth that are approximated on theattachment template 100, the more accurate the placement of theattachment can be. The more tooth surfaces that are approximated, themore accurate the placement can be. Accordingly, an embodiment, as shownin FIG. 1 , can be very accurate if the shapes of the teeth of the jawof the patient have been closely approximated by the surfaces of theattachment template body 104. Three-dimensional printing of attachmenttemplates 100 can be more accurate than previously used manufacturingtechniques in approximating the surfaces of the teeth.

For example, a three-dimensional printed attachment template body 104can have a first surface shaped to conform to contours of exteriorsurfaces of one or more teeth of a patient 102 and can include a portionof the first surface that provides a cavity 106 to form the exteriorsurfaces of an attachment that is to be attached to and protruding fromthe exterior surfaces of one of the one or more teeth 102. In someexamples, the cavity 106 can include one or more openings 107 forinsertion of uncured attachment material 108 into the cavity 106. Theone or more openings 107 can also allow light to enter the cavity tocure the uncured attachment material 108 from a light source 110.

The attachment template body 104 can be formed using a variety ofthree-dimensional printing technologies. For example, the attachmenttemplate body 104 can be three-dimensionally printed via fuseddeposition modeling (FDM), stereolithography (SLA), or selective lasersintering (SLS). The contours of the exterior surfaces of the one ormore teeth 102 of the patient can be scanned and used to create thethree-dimensionally printed attachment template body 104. In someembodiments, the first surface of the body can be shaped to conform tothe facial (e.g., buccal) and/or occlusal surfaces of the teeth 102 ofthe patient.

A portion of the body of the attachment template 104 can be made ofnon-light transmissive material, for example, nylon. The one or moreopenings 107 can permit light from the light source 110 to enter thecavity 106 to cure the uncured attachment material 108 where a portionof the body 104 is made of non-light transmissive material.

FIG. 2 illustrates a three-dimensional printed attachment template 220,an attachment material delivery device 262, and a light source 210,according to a number of embodiments of the present disclosure.

The body 224 may include a structure formed of a 3D printed material andconfigured to receive a patient's teeth 202. The body 224 may be formedof a packable and/or flowable composite and may comprise material thatis translucent or opaque to light. The first surface 242 of the body maybe shaped to interface and/or be received by a patient's cheeks or otherportion of the patient's mouth. The second surface 244 may be shaped toreceive the patient's teeth 202.

The attachment template 220 includes one or more openings 207 to receiveuncured attachment material 228 into a cavity 206 shaped to form anattachment. The cavity 206 has interior surfaces 208 that are used toform the exterior surfaces of the attachment as the uncured attachmentmaterial 250 is cured by a light source 210. The cavity 206 may furthercomprise a vent opening 252 (which may, but need not, be one of the oneor more openings 207) to release gases caused by injecting and/or curingattachment material 228 in the cavity 206.

The cavity 206 can be sized to hold a specific amount of attachmentmaterial 228 that is sufficient to form the desired shaped attachmentneeded for the treatment plan to treat the orthodontic conditions of apatient. The cavity can also be sized sufficient to include anaffixation material, release material, and/or bonding material, forexample.

The attachment template body 224 can have a first surface shaped toconform to contours of exterior surfaces of one or more teeth 202 of apatient. The first surface can include a portion that provides thecavity 206 to form exterior surfaces of the attachment. The attachmentcan be attached to and protruding from the exterior surfaces of one ofthe one or more teeth 202.

The cavity 206 can include a vent 252 to allow air to flow from thecavity, and/or any surplus uncured attachment material 228. The vent 252can be included in the attachment template body 224 to prevent airbubbles from forming in the attachment. Air bubbles in the attachmentcan result in deformation and/or failure of the attachment, for example.

In some embodiments, a portion of the body 224 can permit light from thelight source 210 to enter to cure the attachment material by being madeof a light transmissive material (e.g., transparent). For example, ablue light can be used to cure the uncured attachment material 228. Theuncured attachment material 228 can be exposed to the blue light oranother light from 20 to 40 seconds. Non-visible light or ultraviolet(UV) light may also be used to cure the uncured attachment material 228.For example, the light used to cure the attachment material can have awavelength of 400 nanometers to 500 nanometers. The light from the lightsource 210 can be one or more types, for example, tungsten halogen,light-emitting diode (LED), plasma, arc curing, or laser.

FIGS. 3-8 illustrate attachments having various shapes according to someembodiments. FIG. 3 illustrates a polygonal (e.g., rectangular prism)attachment according to a number of embodiments of the presentdisclosure. An attachment formed from the cavity (e.g., cavity 106 inFIG. 1 ) of the attachment template body (e.g., attachment template body104 in FIG. 1 ) can be one or more shapes including a polygonalattachment 334, for example. The shape can be selected based on thetreatment plan. The polygonal attachment 334 can be affixed to a tooth332 to provide one or more surfaces to contact one or more surfaces of adental appliance during one or more treatment stages. For example, afirst surface of the polygonal attachment 334 can be utilized throughinteraction with one or more surfaces of a first dental appliance whilea second surface of the polygonal attachment 334 is not utilized. Then,later in treatment, the second surface of the polygonal attachment 334is either additionally or alternatively used to interact with one ormore surfaces of a second dental appliance.

FIG. 4 illustrates an ellipsoid attachment according to a number ofembodiments of the present disclosure. An attachment formed from thecavity (e.g., cavity 106 in FIG. 1 ) of the attachment template body(e.g., attachment template body 104 in FIG. 1 ) can be one or moreshapes including an ellipsoid attachment 444, for example. The shape canbe selected based on the treatment plan. The ellipsoid attachment 444can be affixed to a tooth 442 to provide one or more surfaces to contactone or more surfaces of a dental appliance during one or more treatmentstages. For example, a first surface of the ellipsoid attachment 444 canbe utilized through interaction with one or more surfaces of a firstdental appliance while a second surface of the ellipsoid attachment 444is not utilized. Then, later in treatment, the second surface of theellipsoid attachment 444 is either additionally or alternatively used tointeract with one or more surfaces of a second dental appliance.

FIG. 5 illustrates a morphed attachment according to a number ofembodiments of the present disclosure. An attachment formed from thecavity (e.g., cavity 106 in FIG. 1 ) of the attachment template body(e.g., attachment template body 104 in FIG. 1 ) can be one or moreshapes including a morphed attachment 554, for example. The shape can beselected based on the treatment plan. The morphed attachment 554 can beaffixed to a tooth 552 to provide one or more surfaces to contact one ormore surfaces of a dental appliance during one or more treatment stages.For example, a first surface of the morphed attachment 554 can beutilized through interaction with one or more surfaces of a first dentalappliance while a second surface of the morphed attachment 554 is notutilized. Then, later in treatment, the second surface of the morphedattachment 554 is either additionally or alternatively used to interactwith one or more surfaces of a second dental appliance.

FIG. 6 illustrates hook and button attachments according to a number ofembodiments of the present disclosure. An attachment formed from thecavity (e.g., cavity 106 in FIG. 1 ) of the attachment template body(e.g., attachment template body 104 in FIG. 1 ) can be one or moreshapes including a hook 666 and a button 664, for example. The shapescan be selected based on the treatment plan. The hook 666 and/or button664 can be affixed to a tooth 662 to provide one or more surfaces tocontact one or more surfaces of a dental appliance during one or moretreatment stages. For example, a first surface of the hook 666 can beutilized through interaction with one or more surfaces of a first dentalappliance while a second surface of the hook 666 is not utilized. Then,later in treatment, the second surface of the hook 666 is eitheradditionally or alternatively used to interact with one or more surfacesof a second dental appliance. Similarly, a first surface of the button664 can be utilized through interaction with one or more surfaces of afirst dental appliance while a second surface of the button 664 is notutilized. Then, later in treatment, the second surface of the button 664is either additionally or alternatively used to interact with one ormore surfaces of a second dental appliance.

FIG. 7 illustrates a donut attachment according to a number ofembodiments of the present disclosure. An attachment formed from thecavity (e.g., cavity 106 in FIG. 1 ) of the attachment template body(e.g., attachment template body 104 in FIG. 1 ) can be one or moreshapes including a donut attachment 774, for example. The shape can beselected based on the treatment plan. The donut attachment 774 can be anaffixed to a tooth 772 to provide one or more surfaces to contact one ormore surfaces of a dental appliance during one or more treatment stages.For example, a first surface of the donut attachment 774 can be utilizedthrough interaction with one or more surfaces of a first dentalappliance while a second surface of the donut attachment 774 is notutilized. Then, later in treatment, the second surface of the donutattachment 774 is either additionally or alternatively used to interactwith one or more surfaces of a second dental appliance.

FIG. 8 illustrates a bracket attachment according to a number ofembodiments of the present disclosure. An attachment formed from thecavity (e.g., cavity 106 in FIG. 1 ) of the attachment template body(e.g., attachment template body 104 in FIG. 1 ) can be one or moreshapes including a bracket attachment 884, for example. The shape can beselected based on the treatment plan. The bracket attachment 884 can beaffixed to a tooth 882 to provide one or more surfaces to contact one ormore surfaces of a dental appliance during one or more treatment stages.For example, a first surface of the bracket attachment 884 can beutilized through interaction with one or more surfaces of a first dentalappliance while a second surface of the bracket attachment 884 is notutilized. Then, later in treatment, the second surface of the bracketattachment 884 is either additionally or alternatively used to interactwith one or more surfaces of a second dental appliance.

The attachment template can include features that facilitate theattachment forming process and/or removal of the attachment templatefrom the patient's tooth/teeth after the attachment(s) have been curedand bonded to the tooth/teeth. For example, the attachment template caninclude thicker regions that are resistant to deformation during theinjection process. In some cases, the attachment template can includeone or more compliant regions that preferentially bend or break tofacilitate removal of the attachment template. The compliant regions mayinclude one or more slits, perforations, scored regions, thinner regionsand/or regions made of a more compliant material. FIG. 9 illustrates anattachment template including examples of such features.

In the embodiment of FIG. 9 , the attachment template body 904 includesa first attachment region having walls with a first thickness 905-1around a first cavity 906-1. The thickness around the first cavity 906-1may be chosen, in part, on the material of the attachment template, thesize (e.g., volume) of the attachment and/or the injection force.Thicker walls or walls made of a more rigid material are generally moreresistant to deformation. In some embodiments, the walls of theattachment region is at least about 0.5 millimeters (mm). In someembodiments, the walls of the attachment region ranges from about 0.5 mmand about 2.0 mm.

In some embodiments, the walls of the attachment region around a cavitymay have a different thickness than other regions of the body 904. Forexample, the regions of the template around the one or more teeth may bethinner to provide more comfort for the patient. It may also bebeneficial for regions of the attachment template outside of theattachment region to be relatively thin so that the attachment templatemay bend (e.g., twist) for easier removal of the attachment template. Insome cases, the walls of the attachment region(s) have a greaterthickness than a remainder of the body 904. In some instances, theattachment region(s) may be made of a different material than otherregions of the body 904. For instance, the attachment region(s) may bemade of a more rigid material than a remainder of the body 904.

In some embodiments, where the attachment template includes multipleattachment regions, the walls of the attachment regions may be the sameor may vary. For example, the walls of a first attachment region havingthe first thickness 905-1 that may be the same as, or different than,the walls of a second attachment region having a second thickness 905-2.Differences may depend, in part, on the size (e.g., volume) and shape ofthe corresponding first cavity 906-1 and second cavity 906-2. Thicknessdifferences may also depend on the type (e.g., viscosity) of attachmentmaterial injected into the corresponding cavities. For example, anattachment material having a thicker viscosity may require more force toinject the material into the cavity, and therefore may need a strongerattachment region wall. In some cases, different attachment regions maybe made of different materials. For example, the first attachment region905-1 forming the first cavity 906-1 can be made of the same ordifferent material as the second attachment region 905-2 forming thesecond cavity 906-2. The second cavity 906-2 can be used at the sameand/or a different treatment stage than the first cavity 906-1.

The attachment template of FIG. 9 also includes compliant regions 992-1and 992-2 to ease removal of the body 904 from the attachments and fromthe patient's mouth. In some embodiments, the compliant regions 992-1and 992-2 are slits within the body 904. In some embodiments, thecompliant regions 992-1 and 992-2 correspond to perforated regions,scored regions, thinner regions and/or regions made of a more compliantmaterial. In the example of FIG. 9 , the compliant regions 992-1, 992-2can be between the crown of the one or more teeth (e.g., one or moreteeth 102 in FIG. 1 ). In some instances, the compliant regions arewithin the attachment region(s) (e.g., 905-1, 905-2) of the body 904.The body 904 can be configured to preferentially bend (e.g., twist) atthe compliant regions 992-1, 992-2 for easier removal of the body 904from the patient's mouth. The compliant regions 992-1, 992-2 can be alsoprovide flexibility for placement of the body 904 within the patient'smouth. In some embodiments, the body 904 is configured to preferentiallybreak or split at the compliant regions 992-1, 992-2. Splitting the bodymay also allow a number of cavities 906-1, 906-2 to be used at differenttimes during treatment.

Example Computer System(s)

FIG. 10A illustrates a computing system 1000A for use in a number ofembodiments of the present disclosure. For instance, a computing device1036 can have a number of components coupled thereto. The computingdevice 1036 can include a processor 1038 and a memory 1046. The memory1046 can have various types of information including data 1048 andexecutable instructions 1050, as discussed herein.

The processor 1038 can execute instructions 1050 that are stored on aninternal or external non-transitory computer device readable medium(CRM). A non-transitory CRM, as used herein, can include volatile and/ornon-volatile memory.

Volatile memory can include memory that depends upon power to storeinformation, such as various types of dynamic random access memory(DRAM), among others. Non-volatile memory can include memory that doesnot depend upon power to store information.

Memory 1046 and/or the processor 1038 may be located on the computingdevice 1036 or off of the computing device 1036, in some embodiments. Assuch, as illustrated in the embodiment of FIG. 10A, the computing device1036 can include a network interface 1056. Such an interface 1056 canallow for processing on another networked computing device, can be usedto obtain information about the patient (e.g., characteristics of thepatient's mouth, treatment planning information or data used forcreating a treatment plan information about the attachment shape and/orone or more of the templates described herein) and/or can be used toobtain data and/or executable instructions for use with variousembodiments provided herein.

As illustrated in the embodiment of FIG. 10A, the computing device 1036can include one or more input and/or output interfaces 1058. Suchinterfaces 1058 can be used to connect the computing device 1036 withone or more input and/or output devices 1060, 1068, 1076, 1078, 1086.

For example, in the embodiment illustrated in FIG. 10A, the input and/oroutput devices can include a scanning device 1060, a camera dock 1068,an input device 1076 (e.g., a mouse, a keyboard, etc.), a display device1078 (e.g., a monitor), a printer 1086, and/or one or more other inputdevices. The input/output interfaces 1058 can receive executableinstructions and/or data, storable in the data storage device (e.g.,memory 1046), representing a virtual dental model of a patient'sdentition.

In some embodiments, the scanning device 1060 can be configured to scana patient's dentition or one or more dental molds of the patient'sdentition. In one or more embodiments, the scanning device 1060 can beconfigured to scan the patient's dentition, a dental appliance, and/oran attachment directly. The scanning device 1060 can be configured toinput data into the computing device 1036 which can then be used fortreatment planning and/or generating digital 3D models of the patient'sdentition. This information can also be used to estimate the forcesdiscussed herein.

In some embodiments, the camera dock 1068 can receive an input from animaging device (e.g., a 2D or 3D imaging device) such as a digitalcamera, a printed photograph scanner, and/or other suitable imagingdevice. The input from the imaging device can, for example, be stored inmemory 1046.

The processor 1038 can execute instructions to provide a visualindication of a treatment plan, a dental appliance, and/or one or moreattachments on the display 1078. The computing device 1036 can beconfigured to allow a treatment professional or other user to inputtreatment goals. Input received can be sent to the processor 1038 asdata 1048 and/or can be stored in memory 1046.

The data 1048 may include a 3D model of an object to be 3D printed bythe printer 1086. The 3D model may comprise a mathematicalrepresentation of one or more surfaces of the object. The 3D model mayhave been rendered through automated agents or by an operator through,e.g., the techniques discussed further herein. The 3D model may bestored as a digital model file of a 3D virtual representation of a 3Dobject to be printed. The digital model file may be formatted accordingto a variety of formats, such as an Additive Manufacturing File (AMF)(e.g., one that uses sequential layers), an STL file, a fused depositmodeling (FDM) file, etc.

Such connectivity can allow for the input and/or output of data and/orinstructions among other types of information. Some embodiments may bedistributed among various computing devices within one or more networks,and such systems as illustrated in FIG. 10A can be beneficial inallowing for the capture, calculation, and/or analysis of informationdiscussed herein.

The processor 1038, can be in communication with the data storage device(e.g., memory 1046), which has the data 1048 stored therein. Theprocessor 1038, in association with the memory 1046, can store and/orutilize data 1048 and/or execute instructions 1050 for creating and/ormodeling interactions between an attachment and a tooth; interactionsbetween an attachment and one or more appliances; and/or combinations ofinteractions between one or more attachments, one or more teeth, and/orother structure in the mouth of the patient, and/or one or moreappliances for moving teeth; and/or degradation of an attachment; and/orseparation of a portion of an attachment to reveal a hidden portion.

The processor 1038, in association with the memory 1046 can, in additionto or alternatively, store and/or utilize data 1048 and/or executeinstructions 1050 for creating and/or modeling attachment templates,etch trays, removal trays, attachments, and/or bonding and/or releasablematerials, as well as a virtual modeling of such items with or withoutan appliance for moving teeth, and/or one or more teeth. The virtualmodel of the template and/or attachments to attach a dental appliance tothe teeth of a patient can be used to create a dental appliance, thetemplates themselves, removal tools, and/or attachments, for instance,as discussed further herein. The processor 1038 coupled to the memory1046 can, for example, include instructions to cause the computingdevice 1036 to perform a method including, for example, creating atreatment plan based on a virtual model of a jaw of a patient, whereinthe treatment plan includes use of one or more attachments and/ortemplates or other components on the upper and/or lower jaw of apatient.

In some embodiments, the processor 1038 coupled to the memory 1046 cancause the computing device 1036 to perform the method comprisingmodeling a virtual dental attachment based on the treatment plan,wherein the virtual dental attachment is constructed to provide one ormore forces desired by the treatment plan.

In various embodiments, the processor 1038 coupled to the memory 1046can cause the computing device 1036 to perform the method comprisingcreating an attachment template by placing a digital attachment on acrown surface of a tooth of a digital dental model, creating a digitalattachment template from the digital dental model including theattachment on the crown surface of the tooth of the digital dentalmodel, creating an opening in the digital attachment template, andthree-dimensional printing the attachment template based on the digitalattachment template.

Such analysis can be accomplished one or more times for a treatmentplan. For example, if a treatment plan has 30 stages, it would bepossible to have different attachment configurations for each stage orpossibly more, if desired. However, in many instances the attachmenttype, shape, position, and/or orientation may be changed a few timesduring the treatment plan.

Through use of virtual modeling, attachments can be virtually tested andthe best attachment type, shape, position, and/or orientation can beselected without inconveniencing the patient with trial and error ofattachments during treatment. Additionally, use of virtual modeling canalso allow for custom design of attachment shapes that will be suitablefor a specific patient's needs and/or a specific function within an areaof a patient's mouth. From such analysis, different dental attachmentsand other apparatuses can be created from the virtual dental attachmentplacement apparatus data that would be utilized to create theattachments needed for the different stages.

Further, the specialized nature of the design of such attachments canalso allow the attachments to be made from different materials. In thismanner, attachments during a treatment plan or even during one stage canbe of one or more different materials that may provide more specializedforce distribution than was possible with standard attachments.

The executable instructions 1050 may comprise instructions to transforma 3D model of an object into printable portions that can be printed bythe printer 1086. In some implementations, the executable instructions1050 may comprise instructions to “slice” a 3D model, e.g., to convertthe 3D model into a set of thin layers that are to be 3D printed by theprinter 1086. In some implementations, the executable instructions 1050convert a 3D model into a sliced format file (e.g., a G-code file) thatcan be provided to the printer 1086.

In some implementations, the display 1078 may be configured to display a2D rendering of a 3D model of an object to be 3D printed. The 2Drendering may have been developed through simulations, projections,mappings, etc. of the 3D model into a 2D space. The display 1078 mayfurther be configured to display user interface elements to allow anoperator to interact with a 3D model.

In some embodiments, the printer 1086 can be a three-dimensional ordirect fabrication device that can create a dental appliance directlyfrom instructions from the computing device 1036. Embodiments of thepresent disclosure utilizing such technology can be particularlybeneficial for a variety of reasons. For example, such directmanufacture allows for less waste of materials due to less processingsteps and increased specialization of the attachment placementstructure, attachment materials, and/or other components of theappliances described herein.

The printer 1086 may be configured to use additive manufacturingtechniques to print 3D objects using virtual representations of those 3Dobjects. In some implementations, the printer 1086 join and/or solidifymaterial (e.g., polymeric material) based on instructions from theprocessor 1038 to create a 3D object. As noted herein, the printer 1086may receive from the memory 1046 a sliced format file. The printer 1086may successively add material to a 3D object on a layer-by-layer basisusing, e.g., SLA, FDM, etc.

The printer 1086 may print a 3D object at a specified resolution. Theresolution of the printer 1086 may describe layer thickness(es) and/orX-Y resolutions in a convenient format, such as dots per inch (dpi) ormicrometers (μm).

FIG. 10B illustrates an example of an attachment modeling system 1000B,according to some embodiments. The attachment modeling system 1000B mayinclude a virtual tooth representation management engine 1002, a forcesystem analysis engine 1004, a virtual attachment representationmanagement engine 1012, a 3D surface modeling engine 1008, a 3D surfaceexport engine 1010, a virtual tooth representation datastore 1012, atreatment plan datastore 1014, and a virtual attachment datastore 1016.One or more modules of the attachment modeling system 1000B may becoupled to one another or to modules not explicitly shown in FIG. 10B.

The attachment modeling system 1000B may include one or more engines anddatastores. A computer system can be implemented as an engine, as partof an engine or through multiple engines. As used herein, an engineincludes one or more processors or a portion thereof. A portion of oneor more processors can include some portion of hardware less than all ofthe hardware comprising any given one or more processors, such as asubset of registers, the portion of the processor dedicated to one ormore threads of a multi-threaded processor, a time slice during whichthe processor is wholly or partially dedicated to carrying out part ofthe engine's functionality, or the like. As such, a first engine and asecond engine can have one or more dedicated processors or a firstengine and a second engine can share one or more processors with oneanother or other engines. Depending upon implementation-specific orother considerations, an engine can be centralized or its functionalitydistributed. An engine can include hardware, firmware, or softwareembodied in a computer-readable medium for execution by the processor.The processor transforms data into new data using implemented datastructures and methods, such as is described with reference to thefigures herein.

The engines described herein, or the engines through which the systemsand devices described herein can be implemented, can be cloud-basedengines. As used herein, a cloud-based engine is an engine that can runapplications and/or functionalities using a cloud-based computingsystem. All or portions of the applications and/or functionalities canbe distributed across multiple computing devices, and need not berestricted to only one computing device. In some embodiments, thecloud-based engines can execute functionalities and/or modules that endusers access through a web browser or container application withouthaving the functionalities and/or modules installed locally on theend-users' computing devices.

As used herein, datastores are intended to include repositories havingany applicable organization of data, including tables, comma-separatedvalues (CSV) files, traditional databases (e.g., SQL), or otherapplicable known or convenient organizational formats. Datastores can beimplemented, for example, as software embodied in a physicalcomputer-readable medium on a specific-purpose machine, in firmware, inhardware, in a combination thereof, or in an applicable known orconvenient device or system. Datastore-associated components, such asdatabase interfaces, can be considered “part of” a datastore, part ofsome other system component, or a combination thereof, though thephysical location and other characteristics of datastore-associatedcomponents is not critical for an understanding of the techniquesdescribed herein.

Datastores can include data structures. As used herein, a data structureis associated with a particular way of storing and organizing data in acomputer so that it can be used efficiently within a given context. Datastructures are generally based on the ability of a computer to fetch andstore data at any place in its memory, specified by an address, a bitstring that can be itself stored in memory and manipulated by theprogram. Thus, some data structures are based on computing the addressesof data items with arithmetic operations; while other data structuresare based on storing addresses of data items within the structureitself. Many data structures use both principles, sometimes combined innon-trivial ways. The implementation of a data structure usually entailswriting a set of procedures that create and manipulate instances of thatstructure. The datastores, described herein, can be cloud-baseddatastores. A cloud based datastore is a datastore that is compatiblewith cloud-based computing systems and engines.

The virtual tooth representation management engine 1002 may include oneor more automated agents configured to gather virtual representations ofteeth of a patient from the virtual tooth representation datastore 1012.The virtual tooth representation management engine 1002 may provide anidentifier of a patient and retrieve from the virtual toothrepresentation datastore 1012 virtual representations of teeth of thepatient. In various implementations, the virtual tooth representationmanagement engine 1002 renders a 3D virtual representation of teeth fordisplay on a computer display. As an example, the virtual toothrepresentation management engine 1002 may load 3D graphics correspondingto various perspectives (sagittal, median, frontal/coronal,transverse/axial etc. perspectives) of a patient's teeth.

The optional force system analysis engine 1004 may include one or moreautomated agents configured to gather an orthodontic treatment plan fromthe optional treatment plan datastore 1014. In some implementations, theoptional force system analysis engine 1004 is configured to gather froman orthodontic treatment plan a set of positional force systems to applyto a patient's teeth. The positional force systems may include linearforces, torques, anchor forces, etc. that are to be applied to thepatient's teeth over the course of the orthodontic treatment plan. Thepositional force systems may be implemented by aligners, attachments, orsome combination thereof. In some implementations, the optional forcesystem analysis engine 1004 provides identifiers of attachments for thetreatment plan to other modules, such as the virtual attachmentrepresentation engine 1012. The optional force system analysis engine1004 may identify size(s), shape(s), orientation(s), and/or location(s)of the specific attachments.

The virtual attachment representation engine 1012 may include one ormore automated agents configured to gather virtual representations ofone or more attachments from the virtual attachment datastore 1016. Insome implementations, the virtual attachment representation engine 1012receives identifiers of virtual attachments from an attachment templatedesigner; in some, not necessarily exclusive, implementations, thevirtual attachment representation engine 1012 receives identifiers ofvirtual attachments from the optional force system analysis engine 1004.The virtual representations of one or more attachments may take the formof a virtual rendering of the attachment(s), and/or positional datacorresponding to the location(s), orientation(s), etc. of physicalattachments corresponding to the virtual attachments on a patient'steeth.

As noted herein, the virtual attachment representation management engine1012 may include one or more automated agents configured to facilitatecreation of virtual openings that allow for formation of virtualattachments using an attachment template. In some implementations, thevirtual attachment representation management engine 1012 identifies avirtual region near a positions of a virtual representation of anattachment to designate as a virtual opening. The virtual region mayhave a size, shape, and/or contour associated with it. As noted furtherherein, the virtual attachment representation management engine 1012 mayprovide information about identified virtual openings to other modules,such as the 3D surface modeling engine 1008.

The 3D surface modeling engine 1008 may include one or more automatedagents configured to create virtual 3D surface models of 3D virtualrepresentations of teeth and/or virtual representations of one or moreattachments. The 3D surface modeling engine 1008 may facilitatesuperimposition and/or other arrangements of virtual representations ofone or more attachments and 3D virtual representations of teeth. In someimplementations, the 3D surface modeling engine 1008 generates a virtualrepresentation of an attachment over a 3D virtual representation ofteeth using the size(s), shape(s), and/or positions of physicalcounterparts to these virtual items. The 3D surface modeling engine 1008may create a 3D surface model that corresponds to a negative or a moldof the 3D virtual representations of teeth and/or virtualrepresentations of one or more attachments. The 3D surface model mayhave one or more virtual regions for virtual opening(s) associated withthe virtual attachments.

The 3D surface export engine 1010 may include one or more automatedagents configured to export a 3D surface model. The 3D surface exportengine 1010 may save a 3D surface model in a relevant format, configurea 3D surface model for streaming, and/or format a 3D surface model for3D printing, for instance.

The virtual tooth representation datastore 1012 may be configured tostore virtual representations of teeth. The virtual tooth representationdatastore 1012 may index the virtual representations of teeth by patientand/or by stage of a treatment plan. As noted further herein, thevirtual representations of teeth may comprise position(s),orientation(s), etc. of teeth of a patient that is relevant toapplication of orthodontic aligners to the patient. In someimplementations, the virtual representations of teeth areestimates/approximations of a patient's teeth at a beginning, end, orintermediate stage of an orthodontic treatment plan. In someimplementations, virtual representations of teeth are stored as virtualobjects that can be accessed by the engines described herein.

The optional treatment plan datastore 1014 may be configured to storetreatment plan data. The treatment plan data may include instructions toapply aligners and/or attachments to teeth to generate variousorthodontic outcomes. The treatment plan data may, for instance, includeinstructions to apply force positioning systems to teeth at differenttimes in order to achieve translations, rotations, anchors, etc. tothose teeth.

The virtual attachment datastore 1016 may be configured to store virtualrepresentations of attachments. The virtual representations ofattachments may include size parameters, shape parameters, orientationparameters, as well as force parameters related to how variousattachments interact with aligners to achieve orthodontic treatmentoutcomes. In some implementations, virtual representations ofattachments are stored as virtual objects that can be accessed by theengines described herein.

Example Flowcharts of Methods of Operation

FIG. 14 illustrates an example flowchart 1400 of a process for providinginstructions to create an attachment template using a virtual 3D surfacemodel of the attachment template. The flowchart 1400 is discussed inconjunction with the attachment modeling system 1000B, though it isnoted other structures (e.g., the structures of the computer system1000A) may implement at least portions of the flowchart 1400. As anexample, the processor 1038 may provide instructions to execute theexecutable instructions 1050 to perform at least some of the operationsof the flowchart 1400.

At an operation 1402, identifiers of one or more teeth of a patient fortreatment are gathered. In an implementation, the virtual toothrepresentation management engine 1002 receives from a designer or froman automated agent identifiers of teeth of a patient for treatment. Theteeth may include those teeth of a patient undergoing orthodontictreatment according to a treatment plan. In some implementations, theteeth are all or some of the teeth on a jaw (a mandible or maxilla) of apatient. These teeth may be identified by Universal Tooth Number orother convenient formats. These teeth may be identified by a designer ofan attachment template (e.g., a CAD designer) or through an automatedagent configured to facilitate design of an attachment template.

At an operation 1404, a virtual representation of the one or more teethof the patient are gathered. The virtual tooth representation managementengine 1002 may gather from the virtual tooth representation datastore1012 a virtual representation of the teeth that have been identified fortreatment. The virtual representation may comprise position(s),orientation(s), etc. of teeth that are to be identified for treatment.

At an optional operation 1406, a treatment plan for the one or moreteeth may be accessed. The optional force system analysis engine 1004may gather from the optional treatment plan datastore 1014 a treatmentplan for the teeth. The treatment plan may specify positional forcesand/or positional force systems to place on the teeth. The treatmentplan may involve application of aligners and/or attachments in order toeffect application of the positional forces.

At an optional operation 1408, one or more positional force systems toplace on the one or more teeth using one or more aligners in combinationwith one or more dental attachments may be gathered. The optional forcesystem analysis engine 1004 may further identify positional forcesand/or positional force systems based on treatment plans for the teeth.The optional force system analysis engine 1004 may provide identifiersof aligners and/or attachments to achieve the outcomes of a treatmentplan.

At an operation 1410, virtual representations of one or more attachmentsmay be gathered. The virtual attachment representation management engine1006 may gather from the virtual attachment datastore 1016 virtualrepresentations of one or more attachments. In some implementations, theattachments are specified by a designer of an attachment template. Invarious implementations, the attachments (possibly along withcorresponding aligners) are identified as part of a treatment plan bythe optional force system analysis engine 1004. The virtualrepresentations of the attachments may include size(s), shape(s),orientation(s), etc. of the attachments. The virtual representations maycomprise virtual rendering(s) of the one or more attachments.

At an operation 1411, positional identifiers of the one or moreattachments are gathered. The positional identifiers may serve toposition the one or more attachments relative to specific teeth modeledby the virtual representation of the teeth. In various implementations,the positional identifiers are inferred from positional force systems(see optional operation 1408) and/or treatment plans (see optionaloperation 1406). The positional identifiers may also correspond to oneor more positions for attachments input by a designer seeking to designan attachment template. The positional identifiers may correspond topositions of attachment(s) in relation to a patient's teeth.

The virtual representations of the attachments may also comprisepositional data corresponding to positions of the one or moreattachments on the one or more teeth.

At an operation 1412, one or more virtual openings for the virtualrepresentations of the one or more attachments are identified. Thevirtual attachment representation management engine 1012 may facilitateidentification of one or more virtual openings for the virtualrepresentations of the one or more attachments. In variousimplementations, the virtual openings may correspond to physicalopenings in an attachment template for physical attachments to receiveattachment material and/or receive curing radiation.

At an operation 1414, a virtual 3D model of an attachment template iscreated using the virtual representations of the one or more attachmentsand the one or more virtual openings. The 3D surface modeling engine1008 may provide instructions to superimpose virtual representations ofattachments over virtual representations of teeth that have beenidentified. The 3D surface modeling engine 1008 may further provideinstructions to render virtual openings corresponding to physicalopenings that, in the attachment template, may be used to receiveattachment material and/or curing radiation.

At an operation 1416, instructions to 3D print an attachment templateusing the virtual 3D surface model of the attachment template may beprovided. The 3D surface export engine 1010 may provide instructions tosave, stream, and/or 3D print the virtual 3D surface model to create anattachment template.

FIG. 15 illustrates an example flowchart 1500 of a process for 3Dprinting an attachment template. The flowchart 1500 is discussed inconjunction with the structures of the computer system 1000A shown inFIG. 10A, though it is noted other structures may implement theoperations of the flowchart 1500.

At an operation 1502, a virtual 3D surface model of an attachmenttemplate is gathered. The processor 1038 may gather a virtual 3D surfacemodel of an attachment template formed, e.g., by the attachment modelingsystem 1000B and/or stored in the memory 1046 or the datastore 1048.

At an operation 1504, instructions to a 3D printer to 3D print anattachment template using the virtual 3D surface model of the attachmenttemplate are provided. In some implementations, the processor 1038 mayprovide the printer 1086 with computer program instructions to 3D printan attachment template using the virtual 3D surface model of theattachment template. The printer 1086 may correspondingly 3D print anattachment template using the virtual 3D surface model of the attachmenttemplate.

FIG. 16 illustrates an example flowchart 1600 of a process for creatingattachments on a patient's teeth using an attachment template. Theprocess 1600 may be implemented by a dental or orthodontic practitionerto form and/or cure attachments on a patient's teeth.

At an operation 1602, instructions for use of an attachment template maybe reviewed. At an operation 1604, an attachment template may be coupledto a patient's teeth. In various examples, the attachment template 100(see FIG. 1 ) or the attachment template 220 (see FIG. 2 ) may be placedover/adjacent to the facial (e.g., buccal) area of a patient's teeth.Placing the attachment template may include aligning an inner surface ofthe template so that is registers with one or more tooth surfaces of thepatient's dental arch. As described herein, registering can involvematching a shaped surface of the template with a corresponding shapedsurface of one or more teeth. The attachment template can be configuredto place one or more mold cavities in the attachment template adjacentone or more teeth. In some cases, the attachment template is pressed orshifted with respect to the patient's dental arch to assure alignment ofthe of the one or more mold cavities.

At an operation 1606, one or more attachment materials may be placedinto the one or more mold cavities. In some cases, the attachmentmaterial is in a flowable state and is injected into the attachmentmold(s) via one or more openings in the attachment template that provideaccess to the one or more mold cavities. The injecting may be donemanually using, for example a syringe, or automatically using, forexample a pump system. In some cases, the syringe or pump is connectedto the one or more openings via tubing or a needle. Placing (e.g.,injecting) the attachment material(s) can put the one or more teeth incontact with the attachment material(s). As various examples, uncuredattachment material 108 may be placed into an attachment mold formed byopening 107 within cavity 106 (see FIG. 1 ). As another example, uncuredattachment material 228 may be placed into an attachment mold formed byopening 207 within cavity 206 (see FIG. 2 ). In some cases, theattachment template is shifted before and/or during the injecting ofattachment material to assure the correct placement of the attachmentmaterial with respect to the tooth/teeth. The attachment template mayalso be pressed toward the tooth/teeth, for example at the attachmentregion(s), to help seal the attachment template against the tooth/teethand prevent attachment material from escaping during the injecting. Theinjection process may be controlled by the speed of the injecting. Insome cases, the practitioner may rely on manually sensing resistancefeedback during the injection in order to determine whether to speed up,slow down and/or stop the injecting.

In some embodiments, multiple attachment materials are used. Forexample, a first material may be injected first, followed by injecting asecond material. In some cases, the first and second materials may havedifferent properties. For example, the first material may have adifferent viscosity, hardness, compliance and/or adhesive property thanthe second material.

At an operation 1608, the attachment material may be cured within theone or more attachment molds by providing curing radiation for a curingtime. The curing radiation may be shone through the one or more openingsand/or through a transparent portion of the template. As an example ofthis operation, the attachment material 108 (see FIG. 1 ) may be curedwithin an attachment mold by shining light from the light source 110 onthe attachment material 110 for a specified amount of time (e.g., untilthe attachment material 108 cures). As another example of thisoperation, the attachment material 228 (see FIG. 2 ) may be cured withinan attachment mold by shining light from the light source 210 on theattachment material 228 for a specified amount of time (e.g., until theattachment material 228 cures).

After the attachment material is sufficiently cured and bonded to thetooth/teeth, the attachment template may be separated from theattachment(s) and removed from the patient's mouth. In some cases,removing the template involves breaking or cutting the template using atool, such as a cutting tool. In some cases, removing the templateinvolves bending or breaking the template along one or more compliantregions of the template. Once the attachment template is removed, theattachment(s) may undergo one or more post-forming processes. Forinstance, the attachment(s) may be trimmed to remove excess attachmentmaterial. In some cases, the attachment(s) may be shaped to provide aparticular interaction with one or more aligners.

Example Screen Captures

FIG. 11 illustrates screen captures of an implementation of an exampleof a process of creating a digital attachment template according to anumber of embodiments of the present disclosure. The process 1117 caninclude performing a three-dimensional Boolean operation to union anattachment 1106, a gingiva shape 1111, and a crown 1102 of a tooth of adigital dental model to create an inner shape 1112, performing an offsetoperation by a thickness to create an outer shape 1113, performing asubtraction operation to subtract the inner shape 1112 from the outershape 1113 to create a shell shape 1114, and performing a subtractionoperation to subtract the gingiva cut shape 1118 from the shell shape1114 to form an attachment template 1116. An attachment template (e.g.,attachment template 104 in FIG. 1 ) can be three-dimensionally printedbased on the digital attachment template 1116.

The attachment 1106 can be one or more shapes. In some implementations,the shapes are complex shapes that could not have been formed throughthermoforming techniques. For example, the digital attachment can be,but is not limited to, a rectangle, ellipsoid, morphed, hook, button,donut, and bracket. In some embodiments, the attachment 1106 can beselected based on a treatment plan and the treatment plan can be basedon the digital dental model including the crown 1102. The digital dentalmodel can be received or uploaded, for example, from a three-dimensionalscanner. In some examples, the three-dimensional scanner can scan thecontours of the exterior surfaces of one or more teeth of a patient tocreate the digital dental model.

The thickness of the attachment template 1116 can be determined by theoffset operation when creating the outer shape 1113. The thickness canbe selected based on the treatment plan depending on for example, forcesnecessary to move or prevent movement of a tooth and/or forces necessaryto prevent deformation of the opening (e.g., opening 107 in FIG. 1 )and/or cavity (e.g., cavity 106 in FIG. 1 ).

The digital attachment template can be exported as a file. For example,the digital attachment template can be exported as a stereolithographyfile (STL file). The file can be sent to or uploaded to athree-dimensional printer to three-dimensional print the attachmenttemplate. The attachment template can be printed via fused depositionmodeling (FDM), stereolithography (SLA), or selective laser sintering(SLS), for example.

In some embodiments, the process 1117 can be performed to place a secondattachment based on the treatment plan on the first crown surface and/ora second crown surface of a second tooth of the digital dental model.The process 1117 can also be performed to create a second digitalattachment template from the digital dental model including the secondattachment on the second crown surface.

The process 1117 can further include performing a subtraction operationto subtract a cut shape from the digital attachment template 1116 orcreate the cut shape after the attachment template isthree-dimensionally printed using a knife or a scissors, for example.

FIG. 12 illustrates screen captures of an implementation of an exampleof a process of creating an opening in a digital attachment templateaccording to a number of embodiments of the present disclosure. Theprocess 1218 can include placing a digital cut shape 1209 on the digitalattachment template 1203. The cut shape 1209 can be subtracted from thedigital template 1203 to create the digital template 1204 including anopening 1207.

In some embodiments, the cut shape 1209 contacts the attachment 1206 toensure the opening 1207 will allow uncured attachment material to reacha cavity (e.g., cavity 106 in FIG. 1 ) that forms the attachment 1206.For example, the opening 1207 permits insertion of uncured attachmentmaterial (e.g., uncured attachment material 108 in FIG. 1 ) into thecavity of the attachment template 1203. In some examples, the opening1207 can also be used to permit light to enter the cavity of theattachment template.

FIG. 13 illustrates screen captures of an implementation of an exampleof a process of creating an opening in a digital attachment template.The process 1319 can include placing a cut shape 1309-1 or a number ofcut shapes 1309-2, 1309-3 on the digital attachment templates 1303-1,1303-2. The cut shapes can 1309-1, 1309-2, 1309-3 can contact, and insome cases overlap with, the templates 1303-1, 1303-2. The cut shapes1309-1, 1309-2, 1309-3 can be subtracted from the digital templates1303-1, 1303-2 to create the digital template 1304 including a number ofopenings 1307-1, 1307-2.

As shown in FIG. 13 , the cut shapes 1309-1, 1309-2, 1309-3 can includeone or more shapes. In some examples, the cut shapes 1309-1, 1309-2,1309-3 can include one or more wedges, cylinder, polygonal or tubeshapes to form the opening(s). The cut shapes 1309-1, 1309-2, 1309-3 canbe selected based on a treatment plan, which can be based on the digitaldental model of the patient's teeth.

As described above, the methods and apparatuses described herein forforming attachments on the tooth are configured to directly form the oneor more attachments on the tooth of the patient by injecting theflowable material into the template placed on the dental arch (e.g.,over the teeth). The template may be configured so that pressure isexchanged or released by the apparatus, which may include the injectioncomponent in addition to the template or separately from the template.For example, in some variations the template is configured so that thetemplate does not become released from the teeth by the force of theadditional pressure as the flowable material is injected into the cavityof the template. In some variations the cavity may include a pressurerelease hole or opening, that may permit the release of air (or anyother fluid, including liquid) from the cavity as it is displaced by theinjected flowable material. In some variations the cavity may include aseal or seals around the cavity. For example, the region immediatelyaround the cavity on the template may include a sealing material (a ringor perimeter around the cavity, such as an adhesive, hydrogel, etc.)and/or a gasket or other material (silicone, rubber, etc.) that preventsthe force due to the injection from displacing the template off of theteeth.

In some variations the injection may be from a device (injector) thatapplies a negative pressure to the template (e.g., into thecavity/cavities) of the template. The negative pressure may be appliedto draw the flowable material into the cavity and/or to remove air orother material from the cavity as the flowable material is injected.Note that the use of negative pressure in this manner is stillconsidered injection of the material in the context of this disclosure.

For example, in some variations an injector or injection device mayinclude a dual-(or multi-) lumen needle for injecting into the cavity;one lumen may apply the flowable material while the second lumen may beused to vent and/or apply negative pressure.

The arrangement of the hole(s) in the template may be configured asdescribed herein to allow the injection while concurrently venting,while preventing distortion(s) of the formed attachment; in particularthe venting and/or injecting opening(s) may be positioned on a portionof the template such that they are on a portion of the molded attachmentthat is offset from a surface of the attachment which is configured tocontact the dental device (e.g., aligner) when it is worn on the teeth.For example, a vent opening may be on a lateral side (through thetemplate width), an in particular, on a top region, facing the occlusalsurface of the teeth when applied to the teeth. Typically the lateralside of the attachment closet to the occlusal surface either does notengage with the aligner when the aligner is retained by the attachmentand/or does not engage with significant force. Thus imprecision in theshape of the attachment do to the injection and/or vent holes at theselocations may not interfere with the retention of the aligner by theattachment(s) when worn.

The methods and apparatuses configured to design the template(s)described herein may be further configured to account for the optimallocation(s) of the openings, as described above. In some variations, themethod or apparatus for performing the method may determine the positionof the opening(s) based on the predicted forces acting on the attachmentwhen an aligner is worn on the teeth. In particular, the method orapparatus may position the opening(s) in regions in which a minimallevel of force is to be applied.

As already mentioned above any of the templates may be configured to bedestructively removed from the dental arch once the attachments are set;this may be because the attachments include undercut regions (asdescribed above, e.g., in FIG. 6 ) in which the base of the attachmentnearest to the tooth (more proximal to the tooth) is narrower than theregions more distal to the tooth. For example, any of these templatesmay include a frangible structure that may allow the template, andparticularly the portion forming the cavity or a portion of the cavity,may break away as the template is removed, preventing damage to theformed attachment on the tooth.

In some variations the cavity includes an insert (e.g., a mold insert ora form insert) that is pre-loaded into the cavity that forms theundercut regions and may remain behind when the template is removed fromthe teeth; the mold or form may then be separately removed and/orreleased from the attachment after removing the template. The flowablematerial is injected into the cavity and into the mold/form within thecavity to shape the attachment, including in some variations an undercutregion. The mold or form portion may be loose within the cavity and/ormay be held within the cavity by an adhesive, by a frangible connection,or the like (including combinations of these); force applied to removethe template may break the connection, leaving the mold/form on theattachment and on the teeth until they are separately removed afterremoving the template.

The mold/form may be transparent or transmissive to the energy (e.g.,light) used to cross-link or set the flowable material. In somevariations the mold or insert may be impregnated, coated or otherwisemay contain and release a material that may cross-link or set theinjected flowable material.

The methods and apparatuses configured to design the template(s)described herein may be further configured to account for themold/form(s) and may include these in their designs; the mold or formportion that is separately removable from the template may be formed ofthe same material as the template.

When a feature or element is herein referred to as being “on” anotherfeature or element, it can be directly on the other feature or elementor intervening features and/or elements may also be present. Incontrast, when a feature or element is referred to as being “directlyon” another feature or element, there are no intervening features orelements present. It will also be understood that, when a feature orelement is referred to as being “connected”, “attached” or “coupled” toanother feature or element, it can be directly connected, attached orcoupled to the other feature or element or intervening features orelements may be present. In contrast, when a feature or element isreferred to as being “directly connected”, “directly attached” or“directly coupled” to another feature or element, there are nointervening features or elements present. Although described or shownwith respect to one embodiment, the features and elements so describedor shown can apply to other embodiments. It will also be appreciated bythose of skill in the art that references to a structure or feature thatis disposed “adjacent” another feature may have portions that overlap orunderlie the adjacent feature.

Terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention.For example, as used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, steps, operations, elements, components, and/orgroups thereof. As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items and may beabbreviated as “/”.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if a device in thefigures is inverted, elements described as “under” or “beneath” otherelements or features would then be oriented “over” the other elements orfeatures. Thus, the exemplary term “under” can encompass both anorientation of over and under. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly. Similarly, the terms“upwardly”, “downwardly”, “vertical”, “horizontal” and the like are usedherein for the purpose of explanation only unless specifically indicatedotherwise.

Although the terms “first” and “second” may be used herein to describevarious features/elements (including steps), these features/elementsshould not be limited by these terms, unless the context indicatesotherwise. These terms may be used to distinguish one feature/elementfrom another feature/element. Thus, a first feature/element discussedbelow could be termed a second feature/element, and similarly, a secondfeature/element discussed below could be termed a first feature/elementwithout departing from the teachings of the present invention.

Throughout this specification and the claims which follow, unless thecontext requires otherwise, the word “comprise”, and variations such as“comprises” and “comprising” means various components can be co-jointlyemployed in the methods and articles (e.g., compositions and apparatusesincluding device and methods). For example, the term “comprising” willbe understood to imply the inclusion of any stated elements or steps butnot the exclusion of any other elements or steps.

In general, any of the apparatuses and methods described herein shouldbe understood to be inclusive, but all or a sub-set of the componentsand/or steps may alternatively be exclusive, and may be expressed as“consisting of” or alternatively “consisting essentially of” the variouscomponents, steps, sub-components or sub-steps.

As used herein in the specification and claims, including as used in theexamples and unless otherwise expressly specified, all numbers may beread as if prefaced by the word “about” or “approximately,” even if theterm does not expressly appear. The phrase “about” or “approximately”may be used when describing magnitude and/or position to indicate thatthe value and/or position described is within a reasonable expectedrange of values and/or positions. For example, a numeric value may havea value that is +/−0.1% of the stated value (or range of values), +/−1%of the stated value (or range of values), +/−2% of the stated value (orrange of values), +/−5% of the stated value (or range of values), +/−10%of the stated value (or range of values), etc. Any numerical valuesgiven herein should also be understood to include about or approximatelythat value, unless the context indicates otherwise. For example, if thevalue “10” is disclosed, then “about 10” is also disclosed. Anynumerical range recited herein is intended to include all sub-rangessubsumed therein. It is also understood that when a value is disclosedthat “less than or equal to” the value, “greater than or equal to thevalue” and possible ranges between values are also disclosed, asappropriately understood by the skilled artisan. For example, if thevalue “X” is disclosed the “less than or equal to X” as well as “greaterthan or equal to X” (e.g., where X is a numerical value) is alsodisclosed. It is also understood that the throughout the application,data is provided in a number of different formats, and that this data,represents endpoints and starting points, and ranges for any combinationof the data points. For example, if a particular data point “10” and aparticular data point “15” are disclosed, it is understood that greaterthan, greater than or equal to, less than, less than or equal to, andequal to 10 and 15 are considered disclosed as well as between 10 and15. It is also understood that each unit between two particular unitsare also disclosed. For example, if 10 and 15 are disclosed, then 11,12, 13, and 14 are also disclosed.

Although various illustrative embodiments are described above, any of anumber of changes may be made to various embodiments without departingfrom the scope of the invention as described by the claims. For example,the order in which various described method steps are performed mayoften be changed in alternative embodiments, and in other alternativeembodiments one or more method steps may be skipped altogether. Optionalfeatures of various device and system embodiments may be included insome embodiments and not in others. Therefore, the foregoing descriptionis provided primarily for exemplary purposes and should not beinterpreted to limit the scope of the invention as it is set forth inthe claims.

The examples and illustrations included herein show, by way ofillustration and not of limitation, specific embodiments in which thesubject matter may be practiced. As mentioned, other embodiments may beutilized and derived there from, such that structural and logicalsubstitutions and changes may be made without departing from the scopeof this disclosure. Such embodiments of the inventive subject matter maybe referred to herein individually or collectively by the term“invention” merely for convenience and without intending to voluntarilylimit the scope of this application to any single invention or inventiveconcept, if more than one is, in fact, disclosed. Thus, althoughspecific embodiments have been illustrated and described herein, anyarrangement calculated to achieve the same purpose may be substitutedfor the specific embodiments shown. This disclosure is intended to coverany and all adaptations or variations of various embodiments.Combinations of the above embodiments, and other embodiments notspecifically described herein, will be apparent to those of skill in theart upon reviewing the above description.

What is claimed is:
 1. A method of forming an attachment template,comprising: placing an attachment on a crown surface of a tooth of adigital dental model; creating a digital attachment template from thedigital dental model including the attachment on the crown surface ofthe tooth of the digital dental model, wherein the attachment forms acavity on an inner side of the digital attachment template; creating oneor more holes in the digital attachment template that are configured toprovide access for a flowable attachment material into the cavity; andthree-dimensional printing the attachment template based on the digitalattachment template.
 2. The method of claim 1, wherein creating the oneor more holes comprises forming a window that is shaped to define anarea of light cast onto the flowable attachment material.
 3. The methodof claim 1, wherein a cross-sectional area of the one or more holesranges from about 1 square millimeters (mm²) to about 4 mm².
 4. Themethod of claim 1, wherein creating the one or more holes comprisesforming an injection hole for the flowable attachment material to beinjected into the cavity.
 5. The method of claim 4, further comprisingforming a vent hole that allows excess uncured attachment material orair to flow out of the cavity during the injecting.
 6. The method ofclaim 1, wherein creating the one or more holes in the digitalattachment template includes placing a cut shape on the digitalattachment template and subtracting the cut shape from the digitalattachment template.
 7. The method of claim 6, wherein the cut shapecontacts the attachment to create the one or more holes when the cutshape is subtracted from the digital attachment template.
 8. The methodof claim 6, wherein the cut shape overlaps with the digital attachmenttemplate.
 9. The method of claim 1, wherein creating the one or moreholes includes placing cut shapes on the digital attachment template andsubtracting the cut shapes from the digital attachment template.
 10. Themethod of claim 1, wherein creating the one or more holes comprisingcreating multiple holes by: placing one or more cut shapes on thedigital attachment template; and subtracting the one or more cut shapesfrom the digital attachment template to form the multiple holes.
 11. Themethod of claim 1, wherein the digital dental model is based on a scanof a patient's dentition.
 12. The method of claim 1, wherein theattachment includes an undercut region.
 13. The method of claim 1,wherein the attachment has a symmetric shape.
 14. The method of claim 1,wherein the attachment has a non-symmetric shape.
 15. A method offorming an attachment template, comprising: placing an attachment on acrown surface of a tooth of a digital dental model; creating a digitalattachment template from the digital dental model including theattachment on the crown surface of the tooth of the digital dentalmodel, wherein the attachment includes an undercut region and forms acavity on an inner side of the digital attachment template; creating oneor more holes in the digital attachment template, the one or more holesshaped to provide access for a flowable attachment material into thecavity; and forming the attachment template based on the digitalattachment template.
 16. The method of claim 15, wherein forming theattachment template comprises three-dimensional printing the digitalattachment template.
 17. The method of claim 15, wherein creating thedigital attachment template includes forming a frangible structure thatis arranged to break away a portion of the attachment template.
 18. Themethod of claim 15, wherein forming the attachment template comprisesthree-dimensional printing the digital attachment template.
 19. Themethod of claim 15, wherein forming the attachment template comprisesthree-dimensional printing the digital attachment template.
 20. A methodof forming an attachment template, comprising: placing an attachment ona crown surface of a tooth of a digital dental model; creating a digitalattachment template from the digital dental model including theattachment on the crown surface of the tooth of the digital dentalmodel, wherein the attachment includes an undercut region and forms acavity on an inner side of the digital attachment template; creating oneor more holes in the digital attachment template is configured toprovide access for a flowable attachment material into the cavity; andthree-dimensional printing the attachment template based on the digitalattachment template.